Product

1-3 Arrange & Fill
Random Fiber

Using the patented Arrange & Fill method, we produce  1-3 composites using piezo ceramic fibers as active rods, randomly distributed over the composite active area. Typical applications include non-destructive testing (NDT), Sonar single element transducers, air ultrasound transducers, and flow control and measurement.

Innovative production process:
the Arrange & Fill method

Smart Material manufactures 1-3 composites using piezo ceramic fibers as active rods. PZT fiber composites are a cost effective alternative to the Dice & Fill method.

1-3 fiber piezo composites are prepared by epoxy infiltration of fiber bundles and dicing of the cube-shaped blocks perpendicular to the direction of the fibers. This patented method is also called Arrange & Fill. Due to the Arrange & Fill production method, the raw 1-3 fiber composite material is typically blocks up to 10 cm in length and the lateral dimensions of the targeted element.

In addition to slicing elements with the desired resonance frequency of the raw fiber block, the Arrange & Fill method also allows 1-3 fiber composites to be processed into various shapes and forms. This includes precise concave or convex contours for superior broadband ultrasound receiver applications.

The Arrange & Fill manufacturing method is easily scalable to high volume production, which also allows for short lead times, which is a major advantage over the more commonly used Dice & Fill method.

Smart Material offers various standard epoxy and polyurethane systems as the interstitial material for its random fiber composites, often called filler. The different filler materials available allow for operational temperatures ranging from 95°C to 135°C.

1-3 Arrange & Fill Random Fiber Composites

Using piezo ceramic fibers with 105µm, 250µm and 800µm diameter, fill factors of approximately 35%, 65% and 80% are obtained in a randomly distributed cross section.

The random fiber composite shows superior properties for ultrasound transduction which is due to reduced acoustic impedance and high coupling factor. In addition, 1-3 fiber composites with random element distribution provide increased spurious mode suppression as a result of the random spacing.

1-3 Random Fiber Composite product specifications

Resonance Frequencies	80 kHz – 8 MHz
Fill Factors	35%, 65%, 80%
PZT Materials	PZT Navy Type II
Acoustic Impedance	12 MRayl – 27 MRayl
Available Electrodes	CuSn (Copper with Tin flash layer) Au (Gold)
Dimensions	Max. 100mm by 100mm Various round diameters
Coupling Coefficient kt	0.61 – 0.68 Fiber Diameter: Max. frequency Aspect ratio rules apply
Operational Temperatures	Typical: 95°C 135°C on request
Interstitial Materials	Various Epoxy systems

1-3 Random Fiber Composite product selections

Resonance Frequencies

Frequency	Fiber Diameter (Pixel)	Fill Factor	Dimensions (in mm²)
80 kHz – 1 MHz	105µm, 250µm, 800µm	35%, 65%, 80%	max. 100 x 100
1 MHz – 5 MHz	105µm, 250µm	35%, 65%	max. 100 x 100
5 MHz – 8 MHz	105µm	35%	max. 100 x 100

Frequency Tolerances: ± 10% (typical), ± 5% (on request)

Fill Factors

Fill Factor	Fiber Diameter (Pixel)	Frequency
35%	105µm	80 kHz – 8 MHz
65%	250µm	80 kHz – 5 MHz
80%	800µm	80 kHz – 1 MHz

PZT Materials

PZT Material	Di-electric Constant	Frequency
PZT Navy Type II, 5A	1850	80 kHz – 10 MHz

Acoustic Impedance

Acoustic Impedance (MRayl)	Fill Factor
12 MRayl	35%
22 MRayl	65%
27 MRayl	80%

Available Electrodes

Electrode Material	Frequency
CuSn	80 kHz – 1 MHz
CuSn, Au	1 MHz – 8 MHz

Coupling Coefficient kt

Fiber Diameter	Max. Frequency (best kt)
105µm	8 MHz
250µm	4 MHz
800µm	1 MHz

Dimensions

Max. Dimensions	Frequency
100 mm x 100 mm	80 kHz – 5 MHz
65 mm x 65 mm	5 MHz – 8 MHz

Mechanical Tolerances:
< 6mm ± 0.1mm
< 30mm ± 0.2mm
> 30mm ± 0.3mm

Available Diameters
3.18 mm (0.125″)
5.12 mm (0.202″)
5.18 mm (0.204″)
5.68 mm (0.224″)
6.00 mm (0.236″)
6.50 mm (0.256″)
8.20 mm (0.323″)
9.00 mm (0.354″)
9.50 mm (0.374″)
10.00 mm (0.394″)
10.20 mm (0.402″)
12.00 mm (0.472″)
12.70 mm (0.500″)
14.20 mm (0.559″)
15.90 mm (0.626″)
17.50 mm (0.689″)
18.00 mm (0.709″)
19.05 mm (0.750″)
20.00 mm (0.787″)
24.00 mm (0.945″)
25.40 mm (1.000″)
30.00 mm (1.181″)
35.00 mm (1.378″)
37.7 mm (1.480″)

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We look forward to hearing from you.

+49 351 4977 145

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Additional 1-3 composites types

See more available 1-3 composite products manufactured by Smart Material

1-3 Arrange & Fill
Regular Fiber

Piezo ceramic fibers used as active rods, regular distributed over the composite active area.

smart-materials-1-3-composites-dice-fill

1-3 Dice & Fill Composite

Smart Material manufactures 1-3 composites using the commonly used Dice&Fill method.

1-3 Arrange & FillRandom Fiber

Innovative production process: the Arrange & Fill method